Crown-Structured Battery Cell Housing for Stable Heat-Dissipating Modules
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Solution Overview
Problem
Existing battery modules are heavy and require complex connections that are prone to failure, posing challenges for integration into vehicles while ensuring mechanical stability, electrical safety, and ease of recycling.
Innovation Solution
A beaker-like accumulator cell housing with a crenellation or crown structure on the base and closure, featuring protrusions and clips for secure mechanical connection, allows for space-efficient and protected electrical connections, enabling a stable sandwich structure with integrated thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex connections are used to ensure electrical safety and mechanical stability, then reliability improves, but device complexity increases
Solution Approach 1:
The patent combines electrical connections and mechanical support functions into a single integrated busbar structure. The busbar serves both as an electrical conductor connecting cells and as a mechanical support element that provides structural stability, thereby reducing the number of separate components and simplifying the overall connection system while maintaining both electrical safety and mechanical reliability
Solution Approach 2:
The busbar is designed to perform multiple functions simultaneously: it provides electrical connectivity between cells, offers mechanical support to the cell assembly, and contributes to the overall structural stability of the battery module. This multi-functional design reduces device complexity by eliminating the need for separate dedicated electrical connectors and mechanical support structures
2Reliability
If more protective structures are added to protect electrical connections, then reliability improves, but device complexity increases
Solution Approach 1:
The patent integrates protective features directly into the busbar structure itself rather than adding separate protective components. The busbar design incorporates elements that simultaneously provide electrical connection, mechanical support, and protection against environmental factors, thereby achieving connection protection without increasing overall device complexity
Solution Approach 2:
The busbar structure is designed to be self-protecting through its inherent geometric and material properties. The structure itself provides the necessary protection against short circuits, mechanical damage, and environmental exposure without requiring additional protective layers or components, allowing the connection element to serve its own protective needs
3Strength
If heavy materials are used to ensure mechanical stability, then strength improves, but weight increases
Solution Approach 1:
The patent employs composite material strategies where the busbar combines materials with different properties to achieve optimal strength-to-weight ratio. By selecting materials that provide sufficient mechanical strength while minimizing density, the design achieves the required structural stability without excessive weight gain, balancing strength requirements with weight constraints
Solution Approach 2:
The mechanical support function is distributed across multiple busbars and connection points rather than relying on a single heavy structural element. This segmentation allows the use of lighter materials in each individual component while achieving overall mechanical stability through the collective arrangement and geometric configuration of the distributed support structure
4Productivity
If space-efficient connections are implemented, then productivity improves, but manufacturing precision requirements increase
Solution Approach 1:
The busbar connection system incorporates dynamic design features that accommodate manufacturing tolerances and assembly variations. The structure includes flexible elements and tolerance-compensating geometries that allow for precise electrical and mechanical connections even when manufacturing precision varies within acceptable ranges, thereby maintaining productivity without requiring extremely tight manufacturing tolerances
Data Source
AI summary
The invention relates to an accumulator cell housing and a battery or a battery cell module formed from multiple secondary cells on the basis of a uniform accumulator cell housing design. Here, the starting point is a beaker-like structure with a beaker base, a beaker wall (1) and a beaker closure (3) opposite the beaker base. The chemical-physical means necessary for storing electrical energy can be introduced in the beaker cavity. Electrical connections are furthermore provided at least in the region of the beaker closure. Both in or on the beaker base and in or on the beaker closure there is provided a crenellation or crown structure which in each case has multiple spaced-apart protrusions (5, 6). A sandwich structure formation for creating a battery module is produced via a connection of base and cover plates (9, 10) with use of the previously mentioned protrusions of the respective crenellation or crown structures, and, in this regard, besides the improved mechanical stability, an optimised, symmetrical or uniform heat dissipation is possible.